Structural battery pack adhesive coating stackup

Abstract

A battery pack includes an enclosure comprising a first wall and a second wall opposing the first wall, battery cells disposed in an interior of the enclosure between the first wall and the second wall, a first coating and adhesive assembly, and a second coating and adhesive assembly. The first coating and adhesive assembly is configured to structurally couple the battery cells with the first wall of the enclosure and electrically isolate the battery cells from the first wall of the enclosure. The second coating and adhesive assembly is configured to structurally coupling the battery cells with the second wall of the enclosure and electrically isolate the battery cells from the second wall of the enclosure.

1 . A battery cell, comprising:
 a can in which componentry of the battery cell is enclosed; and   a coating disposed on the can, the coating comprising:
 a first segment comprising a first material composition; 
 a second segment separate from the first segment and comprising the first material composition; 
 a third segment extending between the first segment and the second segment and comprising a second material composition different than the first material composition; and 
 a fourth segment separate from the third segment, extending between the first segment and the second segment, and comprising the second material composition. 
   
     
     
         2 . The battery cell of  claim 1 , wherein the first segment contacts a first side of the can and the second segment contacts a second side of the can opposing the first side of the can. 
     
     
         3 . The battery cell of  claim 2 , wherein the third segment contacts a third side of the can, the fourth segment contacts a fourth side of the can opposing the third side, the third side extends from the first side to the second side, and the fourth side extends from the first side to the second side. 
     
     
         4 . The battery cell of  claim 3 , comprising an end cap having the second material composition or a third material composition different than the first material composition and the second material composition, the end cap contacting a fifth side of the can extending between the first side, the second side, the third side, and the fourth side. 
     
     
         5 . The battery cell of  claim 4 , comprising at least one terminal extending through at least one aperture in the end cap. 
     
     
         6 . The battery cell of  claim 1 , wherein the first segment overlaps with the third segment along a portion of the coating, and the first segment overlaps with the fourth segment along an additional portion of the coating. 
     
     
         7 . The battery cell of  claim 1 , wherein the first material composition comprises an ultraviolet (UV) cured spray acrylic. 
     
     
         8 . The battery cell of  claim 1 , wherein the first material composition comprises polyethylene terephthalate (PET), ultraviolet (UV) cured PSA, and primer. 
     
     
         9 . The battery cell of  claim 1 , wherein the third segment comprises a thermal insulation or gap pad. 
     
     
         10 . A battery pack comprising a plurality of battery cells, wherein each battery cell of the plurality of battery cells comprises:
 a can in which componentry of the battery cell is enclosed; and   a coating disposed on the can, the coating comprising:
 a first coating segment disposed on a first side of the can; 
 a second coating segment disposed on a second side of the can opposing the first side; 
 a third coating segment disposed on a third side of the can; and 
 a fourth coating segment disposed on a fourth side of the can opposing the third side, wherein a first portion of the first coating segment overlaps with the third coating segment, a first additional portion of the first coating segment overlaps with the fourth coating segment, a second portion of the second coating segment overlaps with the third coating segment, and a second additional portion of the second coating segment overlaps with the fourth coating segment. 
   
     
     
         11 . The battery pack of  claim 10 , wherein the first coating segment and the second coating segment comprise a first material composition, and the third coating segment and the fourth coating segment comprises a second material composition different than the first material composition. 
     
     
         12 . The battery pack of  claim 10 , wherein the coating comprises an end cap disposed on a fifth side of the can extending between the first side, the second side, the third side, and the fourth side. 
     
     
         13 . The battery pack of  claim 12 , wherein the end cap comprises at least one aperture configured to receive at least one terminal of the battery cell. 
     
     
         14 . The battery pack of  claim 10 , wherein the third coating segment comprises a first body and a first flange extending from the first body, the fourth coating segment comprises a second body and a second flange extending from the second body, and the first flange and the second flange are disposed on a fifth side of the can extending between the first side, the second side, the third side, and the fourth side. 
     
     
         15 . The battery pack of  claim 14 , wherein the first flange and the second flange define at least one gap therebetween, and the at least one gap is configured to receive at least one terminal of the battery cell. 
     
     
         16 . A battery cell, comprising:
 a can in which componentry of the battery cell is enclosed; and   a coating disposed on the can, the coating comprising:
 a first coating segment disposed on a first side of the can, wherein the first coating segment comprises a first material composition; 
 a second coating segment disposed on a second side of the can opposing the first side, wherein the second coating segment comprises the first material composition; 
 a third coating segment disposed on a third side of the can, wherein the third coating segment comprises a second material composition different than the first material composition; and 
 a fourth coating segment disposed on a fourth side of the can, wherein the fourth coating segment comprises the second material composition, a portion of the first coating segment overlaps with respective first portions of the third coating segment and the fourth coating segment, and an additional portion of the second coating segment overlaps with respective second portions of the third coating segment and the fourth coating segment. 
   
     
     
         17 . The battery cell of  claim 16 , wherein:
 the portion of the first coating segment is overwrapped by the respective first portions of the third coating segment and the fourth coating segment such that the portion is between the can and the respective first portions; and   the additional portion of the second coating segment is overwrapped by the respective second portions of the third coating segment and the fourth coating segment such that the additional portion is between the can and the respective second portions.   
     
     
         18 . The battery cell of  claim 16 , wherein:
 the respective first portions of the third coating segment and the fourth coating segment are overwrapped by the portion of the first coating segment such that the respective first portions are between the can and the portion; and   the respective second portions of the third coating segment and the fourth coating segment are overwrapped by the additional portion of the second coating segment such that the respective second portions are between the can and the additional portion.   
     
     
         19 . The battery cell of  claim 16 , wherein:
 the third coating segment comprises a flange contacting a fifth side of the can extending from the first side, the second side, the third side, and the fourth side;   the fourth coating segment comprises an additional flange contacting the fifth side; and   the battery cell comprises at least one terminal extending from the fifth side.   
     
     
         20 . The battery cell of  claim 16 , wherein the first coating segment comprises a first surface area, the second coating segment comprises a second surface area, the third coating segment comprises a third surface area, the fourth coating segment comprises a fourth surface area, the first surface area is less than the third surface area, the first surface area is less than the fourth surface area, the second surface area is less than the third surface area, and the second surface area is less than the fourth surface area.